Komatsu 125-2 Series Diesel Engine Shop Manual SEBM006411 – PDF DOWNLOAD

Komatsu 125-2 Series Diesel Engine Shop Manual SEBM006411 – PDF DOWNLOAD

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Komatsu 125-2 Series Diesel Engine Shop Manual SEBM006411 – PDF DOWNLOAD

Language : English
Pages : 388
Downloadable : Yes
File Type : PDF
Size: 12.9 MB

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Komatsu 125-2 Series Diesel Engine Shop Manual SEBM006411 – PDF DOWNLOAD

The Komatsu 125-2 Series Diesel Engine Shop Manual, also known as the SEBM006411 manual, is a comprehensive guide to servicing, maintaining, and repairing the Komatsu 125-2 series engine. This engine is commonly used in a range of heavy equipment, including excavators, bulldozers, and loaders. The manual is published by Komatsu, a leading manufacturer of heavy equipment and construction machinery, and is designed for use by qualified mechanics and technicians.

The manual is divided into several sections, each of which provides specific information on different aspects of the engine. The sections include:

1. General information: This section provides an overview of the engine, including its specifications, features, and operating principles. It also includes information on safety precautions, tools, and equipment needed for maintenance and repair.
2. Inspection and adjustment: This section provides detailed instructions on how to inspect and adjust various components of the engine, including the cylinder head, valves, fuel system, and cooling system.
3. Engine disassembly and assembly: This section provides step-by-step instructions on how to disassemble and assemble the engine. It includes detailed diagrams and illustrations to help users understand each step of the process.
4. Troubleshooting: This section provides a comprehensive list of potential problems that may arise with the engine, along with diagnostic procedures to help identify and fix these issues.
5. Maintenance: This section provides information on the regular maintenance tasks that should be performed on the engine, including oil changes, filter replacements, and other routine tasks.
6. Reassembly and testing: This section provides detailed instructions on how to reassemble the engine after repairs have been made. It also includes information on how to test the engine to ensure that it is functioning properly.
7. Service data: This section provides detailed technical data on the engine, including torque specifications, compression pressures, and other important information.

The manual is written in clear, concise language and is filled with detailed diagrams and illustrations to help users understand each step of the process. It is an essential tool for anyone who works with Komatsu engines and can help to ensure that the engine is maintained and repaired to the highest standards.

However, it should be noted that the manual is designed for use by qualified mechanics and technicians and should not be used by individuals without the appropriate training and experience. The manual is also specifically for the 125-2 series engine and should not be used as a reference for other engines in the Komatsu lineup.

TABLE OF CONTENTS:

Komatsu 125-2 Series Diesel Engine Shop Manual SEBM006411 – PDF DOWNLOAD

COVER…………………………………………………………………………… 1
CONTENTS………………………………………………………………………… 2
LIST OF REVISED PAGE……………………………………………………………… 3
SAFETY………………………………………………………………………….. 7
SAFETY NOTICE………………………………………………………………… 7
FOREWORD………………………………………………………………………… 9
GENERAL……………………………………………………………………… 9
HOW TO READ THE SHOP MANUAL……………………………………………………. 10
HOISTING INSTRUCTIONS…………………………………………………………. 11
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER………………………… 12
COATING MATERIALS…………………………………………………………….. 14
STANDARD TIGHTENING TORQUE…………………………………………………….. 16
ELECTRIC WIRE CODE……………………………………………………………. 19
CONVERSION TABLE……………………………………………………………… 20
UNITS……………………………………………………………………….. 26
01 General………………………………………………………………………. 27
APPLICABLE MACHINE……………………………………………………………. 28
SPECIFICATIONS……………………………………………………………….. 30
GENERAL ASSEMBLY DRAWING………………………………………………………. 40
ENGINE PERFORMANCE CURVE………………………………………………………. 60
WEIGHT TABLE…………………………………………………………………. 78
11 STRUCTURE AND FUNCTION…………………………………………………………. 79
GENERAL STRUCTURE…………………………………………………………….. 80
INTAKE AND EXHAUST SYSTEM……………………………………………………… 82
INTAKE AND EXHAUST SYSTEM………………………………………………….. 82
AIR CLEANER……………………………………………………………….100
TURBOCHARGER………………………………………………………………102
AFTERCOOLER……………………………………………………………….105
ENGINE BODY…………………………………………………………………..108
CYLINDER HEAD……………………………………………………………..108
CYLINDER BLOCK…………………………………………………………….110
MAIN CIRCULATION PART………………………………………………………112
TIMING GEAR……………………………………………………………….114
VALVE SYSTEM………………………………………………………………116
FLYWHEEL AND FLYWHEEL HOUSING……………………………………………….118
LUBRICATION SYSTEM…………………………………………………………….122
LUBRICATION SYSTEM CHART……………………………………………………122
OIL PUMP………………………………………………………………….124
REGULATOR VALVE……………………………………………………………126
OIL FILTER………………………………………………………………..127
BYPASS FILTER……………………………………………………………..128
OIL COOLER………………………………………………………………..129
FUEL SYSTEM…………………………………………………………………..131
FUEL SYSTEM CHART………………………………………………………….131
FUEL INJECTION PUMP………………………………………………………..132
FUEL 2-STAGE SET CONTROL MOTOR MOUNT…………………………………………138
ENGINE STOP MOTOR, 2-STAGE SET CONTROL MOTOR………………………………….139
MAGNETIC SWITCH AND FUEL SOLENOID……………………………………………144
BOOST COMPENSATOR………………………………………………………….147
FUEL INJECTION NOZZLE………………………………………………………148
FUEL FILTER……………………………………………………………….149
COOLING SYSTEM………………………………………………………………..151
COOLING SYSTEM CHART……………………………………………………….151
WATER PUMP………………………………………………………………..152
THERMOSTAT………………………………………………………………..154
CORROSION RESISTOR…………………………………………………………155
FAN DRIVE…………………………………………………………………156
ELECTRICAL SYSTEM……………………………………………………………..160
ALTERNATOR………………………………………………………………..160
STARTING MOTOR…………………………………………………………….165
ELECTRICAL INTAKE AIR HEATER………………………………………………..168
ACCESSORY…………………………………………………………………….170
AIR COMPRESSOR…………………………………………………………….170
12 TESTING AND ADJUSTING…………………………………………………………..173
ADJUSTING ENGINE SPEED SENSOR…………………………………………………..175
ENGINE BODY…………………………………………………………………..176
ADJUSTING VALVE CLEARANCE…………………………………………………..176
MEASURING COMPRESSION PRESSURE………………………………………………177
FUEL SYSTEM…………………………………………………………………..178
TESTING AND ADJUSTING FUEL INJECTION TIMING…………………………………..178
TESTING AND ADJUSTING FUEL CUT SOLENOID………………………………………184
ADJUSTING ENGINE STOP MOTOR LEVER……………………………………………185
FUEL INJECTION PUMP CALIBRATION DATA…………………………………………187
PERFORMANCE TEST………………………………………………………………218
RUN-IN STANDARD……………………………………………………………218
PERFORMANCE TEST CRITERIA…………………………………………………..222
TROUBLESHOOTING……………………………………………………………….231
POINTS TO REMEMBER WHEN TROUBLESHOOTING………………………………………233
METHOD OF USING TROUBLESHOOTING CHART………………………………………..234
S-1 Starting performance is poor (Starting always takes time)…………………..238
S-2 Engine does not start…………………………………………………..239
(1) Engine does not turn………………………………………………..239
(2) Engine turns but no exhaust comes out (Fuel is not being injected)……….240
(3) Exhaust gas comes out but engine does not start (Fuel is being injected)….241
S-3 Engine does not pick up smoothly (Follow-up is poor)……………………….242
S-4 Engine stops during operations…………………………………………..243
S-5 Engine does not rotate smoothly (hunting)…………………………………244
S-6 Engine lacks output (no power)…………………………………………..245
S-7 Exhaust smoke is black (incomplete combustion)…………………………….246
S-8 Oil consumption is excessive (or exhaust smoke is blue)…………………….247
S-9 Oil becomes contaminated quickly…………………………………………248
S-10 Fuel consumption is excessive…………………………………………..249
S-11 Oil is in cooling water, or water spurts back, or water level goes down……..250
S-12 Oil pressure caution lamp lights up (drop in oil pressure)…………………251
S-13 Oil level rises……………………………………………………….252
S-14 Water temperature becomes too high (overheating)………………………….253
S-15 Abnormal noise is made…………………………………………………254
S-16 Vibration is excessive…………………………………………………255
TESTING AND ADJUSTING TOOL LIST…………………………………………………256
TESTING AND ADJUSTING DATA……………………………………………………..258
13 DISASSEMBLY AND ASSEMBLY………………………………………………………..271
DISASSEMBLY…………………………………………………………………..271
SPECIAL TOOL LIST………………………………………………………….272
1. Starting motor assembly………………………………………………….273
2. Engine oil cooler assembly……………………………………………….273
3. Setting to tool A1 (overhaul stand)……………………………………….273
4. Fan……………………………………………………………………274
5. Engine mounts…………………………………………………………..274
6. Air cleaner, bracket assembly…………………………………………….274
7. Turbocharger, exhaust manifold assembly……………………………………275
8. Corrosion resistor and piping, wiring……………………………………..275
9. Engine oil filter……………………………………………………….275
10. Lubrication valve………………………………………………………276
11. Fuel filter……………………………………………………………276
12. Fuel injection pipes……………………………………………………276
13. Aftercooler assembly……………………………………………………276
14. Fuel injection pump assembly…………………………………………….277
15. Alternator assembly…………………………………………………….277
16. Thermostat housing, water pump…………………………………………..278
17. Fan pulley, drive assembly………………………………………………278
18. Front support………………………………………………………….278
19. Crankshaft pulley, vibration damper………………………………………279
20. Air vent tube, spill pipe……………………………………………….279
21. Head covers……………………………………………………………279
22. Nozzle holders…………………………………………………………279
23. Rocker arms……………………………………………………………280
24. Crossheads…………………………………………………………….280
25. Push rods……………………………………………………………..280
26. Rocker arm housings…………………………………………………….280
27. Cylinder head assemblies………………………………………………..281
28. Oil pan……………………………………………………………….281
29. Flywheel………………………………………………………………282
30. Rear seal……………………………………………………………..282
31. Flywheel housing……………………………………………………….283
32. Front cover……………………………………………………………283
33. Fuel injection pump drive gear…………………………………………..283
34. Cam follower covers…………………………………………………….284
35. Cam followers………………………………………………………….284
36. Camshaft………………………………………………………………284
37. Oil pump………………………………………………………………285
38. Idler gear…………………………………………………………….285
39. Oil suction pipe……………………………………………………….285
40. Piston and connecting rod assembly……………………………………….286
41. Crankshaft…………………………………………………………….287
42. Piston cooling nozzle…………………………………………………..288
43. Cylinder liner…………………………………………………………289
ASSEMBLY……………………………………………………………………..291
1. Cylinder liner………………………………………………………….293
2. Piston cooling nozzle……………………………………………………295
3. Crankshaft……………………………………………………………..295
4. Piston and connecting rod assembly………………………………………..298
5. Oil suction pipe………………………………………………………..303
6. Idler gear……………………………………………………………..303
7. Oil pump……………………………………………………………….303
8. Camshaft……………………………………………………………….304
9. Cam followers…………………………………………………………..304
10. Cam follower covers…………………………………………………….304
11. Drive gear of fuel injection pump………………………………………..305
12. Fuel injection pump assembly…………………………………………….306
13. Adjusting fuel injection timing………………………………………….307
14. Front cover……………………………………………………………308
15. Crankshaft pulley, vibration damper………………………………………308
16. Flywheel housing……………………………………………………….308
17. Rear seal……………………………………………………………..310
18. Flywheel………………………………………………………………312
19. Oil pan……………………………………………………………….314
20. Cylinder head assemblies………………………………………………..314
21. Rocker arm housings…………………………………………………….316
22. Push rods……………………………………………………………..316
23. Crossheads…………………………………………………………….317
24. Rocker arms……………………………………………………………317
25. Adjusting valve clearance……………………………………………….318
26. Nozzle holders…………………………………………………………318
27. Head covers……………………………………………………………319
28. Spill pipe, air vent tube……………………………………………….319
29. Pulley, front support…………………………………………………..319
30. Drive sensor, tubes, bracket…………………………………………….320
31. Water pump, thermostat housing…………………………………………..320
32. Alternator assembly…………………………………………………….321
33. Adjusting V-belts………………………………………………………321
34. Aftercooler assembly……………………………………………………321
35. Fuel injection pump pipes……………………………………………….322
36. Lubrication valve………………………………………………………322
37. Engine oil filter………………………………………………………323
38. Corrosion resistor……………………………………………………..323
39. Turbocharger, exhaust manifold assembly…………………………………..323
40. Air cleaner……………………………………………………………324
41. Engine mounts………………………………………………………….324
42. Fan…………………………………………………………………..325
43. Resetting engine in engine stand…………………………………………325
44. Engine oil cooler assembly………………………………………………325
45. Starting motor assembly…………………………………………………325
Filling with oil…………………………………………………………..325
14 MAINTENANCE STANDARD……………………………………………………………327
INTAKE AND EXHAUST SYSTEM………………………………………………………328
TURBOCHARGER………………………………………………………………328
ENGINE BODY…………………………………………………………………..330
CYLINDER HEAD……………………………………………………………..330
VALVE AND VALVE GUIDE………………………………………………………332
ROCKER ARM SHAFT…………………………………………………………..334
CROSSHEAD…………………………………………………………………335
CYLINDER BLOCK…………………………………………………………….336
CYLINDER LINER…………………………………………………………….338
CRANKSHAFT………………………………………………………………..339
CAMSHAFT………………………………………………………………….340
CAM FOLLOWER AND PUSH ROD…………………………………………………..341
TIMING GEAR……………………………………………………………….342
PISTON, PISTON RING AND PISTON PIN…………………………………………..344
CONNECTING ROD…………………………………………………………….348
VIBRATION DAMPER…………………………………………………………..349
FLYWHEEL AND FLYWHEEL HOUSING……………………………………………….350
COOLING SYSTEM………………………………………………………………..351
WATER PUMP AND THERMOSTAT…………………………………………………..351
OIL COOLER………………………………………………………………..352
LUBRICATION SYSTEM…………………………………………………………….353
OIL PUMP………………………………………………………………….353
MAIN RELIEF VALVE………………………………………………………….354
REGULATOR VALVE AND SAFETY VALVE…………………………………………….355
ACCESSORY…………………………………………………………………….356
AIR COMPRESSOR…………………………………………………………….356
15 REPAIR AND REPLACEMENTOF PARTS…………………………………………………..357
REPLACING VALVE SEAT INSERTS……………………………………………………358
REPLACING NOZZLE HOLDER SLEEVE………………………………………………….362
REPLACING VALVE GUIDE………………………………………………………….364
REPLACING CROSS HEAD GUIDE……………………………………………………..364
GRINDING THE VALVE…………………………………………………………….365
GRINDING THE FITTING FACE OF CYLINDER HEAD……………………………………….365
REPLACING CAM BUSHING………………………………………………………….366
REPLACING CAM GEAR…………………………………………………………….368
REPLACING FLYWHEEL RING GEAR……………………………………………………368
PRESSURE TEST…………………………………………………………………369
REPLACING ENGINE REAR SEAL……………………………………………………..370
REPLACING CONNECTING ROD SMALL END BUSHING……………………………………….375
REPLACING MAIN BEARING CAP……………………………………………………..376
GRINDING CRANKSHAFT……………………………………………………………379
REPLACING WEAR SLEEVE (When equipped with sleeve)…………………………………388